Chapter 6 Control System Documentation

75
Control System
Documentation
By Fred Meier
Topic Highlights
Reasons for Documentation
Types of Documentation
Process Flow Diagram (PFD)
Piping and Instrument Diagrams (P&IDs)
Loop Numbering
Instrument Lists
Specification Forms
Logic Diagrams
Location Plans (Instrument Location Drawings)
Installation Details
Loop Diagrams
Standards and Regulations
Mandatory Standards
Consensus Standards
Operating Instructions
6.1 Reasons for Documentation
The documentation used to define modern control systems has evolved over the past 50 years. Its pur-
pose is to impart, efficiently and clearly, to a knowledgeable viewer enough information so that the
result is an operating plant producing the desired product. The documents described in this chapter
form a typical set for use in the design of a continuous process plant. Some of the documents are also
used in other process types. The typical set is not necessarily a standard set. Some designs may not
include all of the described documents, and some designs include documents not described.
All of the illustrations and much of the description used in this section were published in 2004 by ISA
in Instrumentation and Control System Documentation by Frederick A. Meier and Clifford A. Meier. That
book includes many more illustrations and much more explanation.
ISA is the abbreviation for The Instrumentation, Systems, and Automation Society. For this reason,
this section uses the term automation and control (A&C), rather than instrument and control
(I&C) used in the Meiers book to describe the engineers and designers developing the control system
documentation.
Chapter 6 Control System Documentation
A GUIDE TO THE AUTOMATION BODY OF KNOWLEDGE, 2nd Edition
76 BASIC CONTINUOUS CONTROL I
6.2 Types of Documentation
Descriptions and typical sketches are included for the following:
Process Flow Diagrams (PFD)
Piping and Instrument Diagrams (P&ID)
Loop Numbering
Instrument Lists
Specification Forms
Logic Diagrams
Location Plans (Instrument Location Drawings)
Loop Diagrams
Standards and Regulations
Operating Instructions
Figure 6-1, or the timeline, illustrates a possible sequence for document development. Information
from one document is used to develop succeeding documents.
Figure 6-1: Instrument Drawing Schedule
E
I
E
I
Time Intervals
1 2 3 4 5 6 7 8 9 10 11 12
Process Diagram
P&ID
Instrument List
Specification Form
Logic Diagram
Location Plans
Loop Diagrams
Typical % of Control Systems Engr. Hours Legend
P&IDs 25%
Instrument List 5%
Spec. Forms 25%
Logic Diagrams 10%
Location Plans 5%
Installation Details 5%
Loop Diagrams 25%
Start of Activity
Issued for Engineering
Issued for Information
Issued for Construction
Chapter 6: Control System Documentation 77
The time intervals vary. The intervals might be days, weeks, or months, but the sequence remains the
same. The documents listed are not all developed or used solely by a typical automation and control
group (A&C). However, the A&C group contributes to, and uses, the information contained in them
during plant design.
6.3 Process Flow Diagram (PFD)
A Process Flow Diagram defines a process schematically. PFDs are most valuable for continuous pro-
cess chemical plants. The PFD shows what and how much of each product a plant might make;
descriptions and quantities of the raw materials necessary; by-products produced; critical process con-
ditionspressures, temperatures, and flows; necessary equipment; and major process piping.
Figure 6-2 shows a simple PFD of a knockout drum, which separates the liquid from a wet gas stream.
Process engineers frequently produce PFDs. Some PFDs include basic, importantor high-costA&C
components. There is no ISA standard for PFDs, but ISA-5.1-1984 (R1992) Instrument Symbols and Iden-
tification and ISA-5.3-1983 Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic,
and Computer Systems contain symbols that can be used to show A&C components.
Batch process plants may configure their equipment in various ways, as raw materials and process
parameters change. Many different products are often produced in the same plant. A control recipe, or
formula, is developed for each product. A PFD may be developed for each recipe.
Figure 6-2: Process Flow Diagram
STREAM
NUMBER
FLOW DESCRIPTION TEMP PRESSURE SP GRAVITY
1
2
3
10,000#/Hr
1,000#/Hr
9,000#/Hr
WET GAS
DEGASSED MATERIAL
LIGHT ENDS TO FLARE
90 - 180 F
70 - 170 F
80 - 140 F
20 psi
50 psi
4 psi
-
-
0.9 AT 60F
ISA COURSE FG15
PROCESS FLOW DIAGRAM
PLANT 001 KNOCKOUT DRUM 0-001
DRG #PFD-1
1
3
2 TO SEPARATOR
TO FLARE
D-001
G-005
6.4 Piping and Instrument Diagrams (P&ID)
The acronym P&ID is widely understood within the process industries to mean the principal document
used to define the processthe equipment, piping, and all A&C components. ISAs Automation, Sys-
tems, and Instrumentation Dictionary definition for P&ID tells us what they do. P&IDs show the inter-
connection of process equipment and instrumentation used to control the process.
1
P&IDs are developed in steps by members of the various design disciplines as a project proceeds. Infor-
mation placed on a P&ID by one discipline is used by other disciplines as the basis for their design.
The P&ID shown in Figure 6-3 has been developed from the PFD in Figure 6-2. The P&ID includes the
control system definition using symbols from ISA-5.1 and 5.3. There are two electronic loops which
are part of the shared display/distributed control system (DCS): FRC-100, a flow loop with control and
recording capability, and LIC-100, a level loop with control and indicating capability. There is one
field-mounted pneumatic loop, PIC-100, with control and indication capability. There are several
switches and lights on a local (field) mounted panel, including hand operated switches and lights HS
and ZL-400, HS and HL-401, and HS and HL-402. There are other control system components shown,
in addition to the above. The P&ID now includes more piping and mechanical equipment details.
6.4.1 Loop Numbering
Letter designations and tag numbers identify all A&C components. All devices in a loop have the same
tag number but different letter designations.
Figure 6-4 consists of LT-100, a field mounted electronic transmitter; LI-100, a field mounted elec-
tronic indicator; LIC-100, a level controller which is part of the DCS; LY-100, a current-to-pneumatic
(I/P) converter; and LV-100, a pneumatic butterfly control valve. ISA-5.1 states that loop numbers
may be parallel, requiring a new number sequence for each process variable, or serial, using a single
numeric sequence for all process variables. Figure 6-3: P&ID uses a parallel numbering system. There
is a flow loop FRC-100, a level loop LIC-100, and temperature loop TI-100. The level gauges, pressure
gauges, and thermometers all are numbered starting with 1: LG-1, PI-1, TI-1.
Figure 6-5 shows how tag marks may also identify the loop location or service. Other numbering sys-
tems are used that tie instruments to a P&ID, a piece of equipment or a location.
6.5 Instrument Lists
The Instrument List (or instrument index) is an alphanumeric listing of all tag-marked components.
Each tag mark will reference the relevant drawings and documents for that device.
Figure 6-6 is a partial listing which includes the level devices on D-001K.O. drum: LG-1, level
gauge; LT-100, level transmitter; and LI-100, level indicator (all from Figure 6-3: P&ID). In addition,
the list shows other instruments on other P&IDs, not included. Figure 6-6 has six columnsfor P&ID,
Spec Form, Req. #, Location Plan, Installation Detail, and Piping Drawing.
The Instrument List is developed by the A&C group. There is no ISA standard defining an Instrument
List. With the advent of computer-aided design techniques, the Instrument List may contain a large
number of columns for various uses during project design, construction, and operation.
6.6 Specification Forms
The A&C group defines the tag-marked devices so suppliers may quote and supply the correct device.
A Specification Form (or data sheet) is filled out for each device.
1. The Automation, Systems, and Instrumentation Dictionary, 4
th
edition (ISA, 2003), pg. 273.
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Let's look at LT-100 from Figure 6-3. The P&ID symbol defines it as an electronic displacement-type
level transmitter.
Figure 6-7 is the completed Specification Form for LT-100. This form is from ISA-20-1981, Specification
Forms for Process Measurement of Control Instruments, Primary Elements and Control Valves. There are many
variations of Specification Forms. Most engineering contractors have developed a set, some control
component suppliers have their set, and ISA has another newer set in technical report, ISA-
Figure 6-4: Level Loop LIC-100
Figure 6-5: Instrument Numbering
LY
100
I/P
LV
100
2"
2"
4
3
1"
1"
300S
2" 150 CS 005
LIC
100
LI
100
AT
LV 100
BYPASS
LT
100
1 1/2"
1 1/2"
1"
2"
2"
Use Basic Number if project is small and there are no area,
unit, or plant numbers:
Basic Number FT-2 or FT-02 or FT-002
If project has a few areas, units, or plants (9 or less), use the
first digit of the plant number as the tag number:
FT-102 (1 = area, unit, or plant number)
If project is divided into area, units, or plants:
1-FT002
01-FT002
001-FT002
TR20.00.01-2001, Specification Forms for Process Management & Control - Part 1: General Considerations. The
purpose of all of the forms is to aid the A&C group to organize the information needed to fully and
accurately define control components so they may be quoted on, and supplied, by vendors. Specifica-
tion Forms are filled out by the A&C group. Their development is a significant part of the group's
effort.
6.7 Logic Diagrams
Continuous process control is shown clearly on P&IDs. Different presentations are needed for on/off
control. Logic Diagrams are one form of these presentations. ISA's set of symbols are defined in ISA-
5.2-1976(R1992) - Binary Logic Diagrams for Process Operations.
ISA symbols AND, OR, NOT and MEMORY (FLIP-FLOP) with an explanation of their meaning are
shown in Figures 6-8 and 6-9. Other sets of symbols and other methods may be used to document on/
off control. Some examples: text descriptions, a written description of the on/off system; ladder dia-
grams; or electrical elementaries.
Some designers develop a Functional Specification or Operation Description to document the entire
system. These documents usually include a description of the on-off control of the process.
A motor start circuit is shown in Figure 6-10 in ISA logic form and also by an elementary diagram.
6.8 Location Plans (Instrument Location Drawings)
There is no ISA standard that defines a Location Plan or an Instrument Location Drawing. Location
Plans show the location and elevation of control components on plan drawings of a plant.
Figure 6-11 shows one approach for a Location Plan. It shows the approximate location and elevation
of the tag-marked devices included on the P&ID, Figure 6-3, air supplies for the devices, and intercon-
nection tubing needed to complete the pneumatic loop. Other approaches to Location Plans might
include conduit and cabling information and fitting and junction box information. Location Plans are
developed by the A&C or electrical groups. They are used during construction and by maintenance
personnel after the plant is built to locate the various devices.
Figure 6-6: A Typical Instrument List
Tag # Desc. P&ID # Spec REQ # Location Install. Piping Drawing
Form # Plan # Detail
LG-1 D-001-K.O. Drum 1 L-1 L-1 ISO-010
LG-2 D-001 Distil. Column 2 L-1 L-1 ISO-015
LG-3 C-002 Stripper 3 L-1 L-1 ISO-016
LT-100 D-001 K.O. Drum 1 L-100 T-1 LP-1 ID-001 ISO-010
LI-100 D-001 K.O. Drum 1 I-100 I-1 LP-1 ID-002
LT-101 C-001- Distil. Column 2 L-100 T-1 LP-4 ID-001 ISO-015
LT-102 C-002 Stripper 3 L-100 T-1 LP-5 ID-001 ISO-016
6.9 Installation Details
Installation Details define the requirements to correctly install the tag-marked devices. The Installation
Details show process connections, pneumatic tubing, or conduit connections, insulation and winteriz-
Figure 6-7: Level Instrument - Specification Form
SHEET OF
NO BY DATE REVISION
0 FAM 12/15/2003
BY CHK'D
FAM CHK CAM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31 Sp. Gr.: Upper Sp. Gr.: Lower
32 Press. Max. Normal
33 Temp. Max. Normal
34
35
36 Airset Supply Gage
37
38
39 Contact: No. Contact: Form
40
41
42
43
44
45
46
47
48
.9 @ 60 F
50 PSI 4 PSI
LATER
LATER
DEGASSED MTL.
400 F 90-150 F
24Vdc from shared
display
INCREASE
INTEGRAL
4-20 mAdc
SIDE
1981 ISA
LT-100
01-D-001
C.S.
300 psi
1 1/2" TOP
OPTIONS
BODY/CAGE
DISPLACER
OR FLOAT
XMTR/CONT.
SERVICE
LEVEL INSTRUMENTS
(DISPLACER OR FLOAT)
300 psi FLG
NEMA 8
WET GAS
MFG. STD.
304 S.S.
Service
NOTES:
Gage Glass Model No.
Displacer Spring/Tube Mtl.
Lower Liquid
Function
Control Modes
Upper Liquid
ISA FORM S20.26
Model Number
Manufacturer
Output
Mounting
Output Action: Level Rise
Enclosure Class
Differential
Elec. Power or Air Supply
Rating
Orientation
Cooling Extension
Conn Size & Location Upper
Type
Case Mounting
Type
Disp. or Float Material
Tag Number
Line Number / Vessel Number
Type
Conn Size & Location Lower
Rotatable Head
Dimensions
DATE
1234 1/3/2003
CONTRACT
LF
J-6 J-12
REQ. - P.O.
APPR.
SPEC. NO. REV.
321 0
TRANSMITTER
NOT REQ
300 psi FLG
1 1/2" BTM
NOT REQ
Contact Rating
Action of Contacts
Gage Glass Connections
K.O. DRUM
Insertion Depth
Displacer Extension
48"
Body or Cage Material
LEFT HAND
ing requirements, and support methods. There is no ISA Standard that defines Installation Details.
However, libraries of Installation Details have been developed and maintained by engineering contrac-
tors, A&C device suppliers, some plant owners, installation contractors, and some individual designers.
They all have the same aimsuccessful installation. They may differ in details as to how to achieve it,
however.
Figure 6-12 shows one approach. This drawing includes a material list to aid in procuring installation
materials and assisting installation personnel.
Installation Details may by developed by the A&C group during the design phase. However, they are
sometimes developed by the installer during construction or by an equipment supplier for the project.
6.10 Loop Diagrams
ISAs Automation, Systems, and Instrumentation Dictionary defines a Loop Diagram as a schematic repre-
sentation of a complete hydraulic, electric, magnetic or pneumatic circuit.
1
The circuit is called a loop.
For a typical loop see Figure 6-4. ISA-5.4-1991, Instrument Loop Diagrams presents six typical loop dia-
Figure 6-8: Binary Logic Symbols - AND & OR
Figure 6-9: Binary Logic Symbols - NOT & MEMORY (FLIP-FLOP)
1. Ibid., pg. 299.
Figure 6-10: Motor Start Logic
Figure 6-11: Location Plan, Approach A
LOGIC
PUMP
START
PUMP
STOP
MOTOR STARTER,
PUMP MOTOR
OVERLOAD
MOTOR STARTER,
RESET PUMP
MOTOR
PUMP
STARTS
A
S
R
ELEMENTARY
START
BUTTON
STOP
BUTTON
OVERLOAD
RELAY CONTACTS
CI COIL
CONTACT
COIL
grams, two each for pneumatic, electronic, and distributed control (DCS). One of each type shows the
minimum items required, and the other shows additional optional items.
Figure 6-13 is a Loop Diagram for electronic flow loop FIC-301. Loop Diagrams are not always
included in a design package. Some plant owners do not believe they are worth their cost, which is
significant. Loop Diagrams are sometimes produced by the principal project A&C supplier, the installa-
tion contractor, or by the plant owner's operations, maintenance, or engineering personnel. Some-
times Loop Diagrams are produced on an as needed basis after the plant is running.
Figure 6-12: Installation Detail, Type 2 - Flow Transmitter
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6.11 Standards and Regulations
6.11.1 Mandatory Standards
Federal, state, and local laws establish mandatory requirements: codes, laws, regulations, require-
ments, etc. The Food and Drug Administration issues Good Manufacturing Practices. The National Fire
Protection Association (NFPA) issues Standard 70, the National Electric Code (NEC). The United States
government manages about 50,000 mandatory standards. The Occupational Safety and Health
Administration (OSHA) issues many regulations including government document 29 CFR 1910.119,
Process Safety Management of Highly Hazardous Chemicals (PSM). There are three paragraphs in the PSM
which list documents required if certain hazardous materials are handled. Some of these documents
require input from the plant A&C group.
6.11.2 Consensus Standards
Consensus Standards include recommended practices, standards, and other documents developed by
professional societies and industry organizations. The standards developed by ISA are the ones used
most often by A&C personnel. Relevant ISA standards include: ISA-5.1-1984-(R1992), Instrumentation
Symbols and Identification, which defines symbols for A&C devices; ISA-5.2-1976-(R1992), Binary Logic
Diagrams for Process Operations, which provides additional symbols used on Logic Diagrams; and ISA-
5.3-1983, Graphic Symbols for Distributed Control/ Shared Display Instrumentation, Logic and Computer Sys-
tems, which contains symbols useful for DCS definition. The key elements of ISA-5.3 are now included
in ISA-5.1, and ISA-5.3 will be withdrawn in the future.
ISA-5.4 Instrument Loop Diagrams includes additional symbols and six typical instrument Loop Dia-
grams. ISA-5.5 Graphic Symbols for Process Displays establishes a set of symbols used in process display.
Other ISA standards of interest include ISA-20-1981, Specification Forms for Process Measurement and Con-
trol Instruments, Primary Elements and Control Valves. ISA TR20.00.01-2001, Specification Forms for Process
Control and Instrument, Part 1: General Considerations, updates ISA-20. ANSI/ISA-84.00.01-2004 - Func-
tional Safety: Safety Instrumented Systems for the Process Industry Sector, defines the requirements for safe
systems. ANSI/ISA-88.01-1995, Batch Control Part I Models and Terminology, shows the relationships
involved between the models and the terminology.
In addition to ISA, other organizations develop documents to guide professionals. These organizations
include American Petroleum Institute, American Society of Mechanical Engineers, National Electrical
Manufacturers Association, Process Industry Practice, and Technical Association of the Pulp and Paper
Industry.
6.12 Operating Instructions
Operating Instructions are necessary to operate a complex plant. They range from a few pages describ-
ing how to operate one part of a plant to a complete set of books covering the operation of all parts of
a facility. They might be included in a functional specification or an operating description. There is no
ISA standard to aid in developing Operating Instructions. They might be prepared by a group of
project, process, electrical and A&C personnel during plant design. Some owners prefer plant opera-
tions personnel to prepare these documents. The Operating Instructions guide plant operators and
other personnel during normal and abnormal plant operation, including start-up, shutdown, and
emergency operation of the plant.
OSHA requires operating procedures for all installations handling hazardous chemicals. Their require-
ments are defined in government document 29 CFR 1910.119(d) Process Safety Information, (f ) Operat-
ing Procedures and (l) Management of Change. For many types of food processing and drug
manufacturing, the Food and Drug Administration issues Good Manufacturing Practices.
About the Author
Fred Meier's career in engineering and engineering management spans 50 years. He has been an
active member of ISA for more than 40 years. He has earned an ME from Stevens Institute of Technol-
ogy and an MBA from Rutgers University and has held Professional Engineer licenses in the United
States and in Canada. Fred and his son, Clifford, are authors of Instrumentation and Control System Docu-
mentation published by ISA in 2004. He and his wife Jean live in Chapel Hill, NC.

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